EP3610215B1 - Integration of ultrasonic additive manufactured thermal structures in brazements - Google Patents
Integration of ultrasonic additive manufactured thermal structures in brazements Download PDFInfo
- Publication number
- EP3610215B1 EP3610215B1 EP18720441.7A EP18720441A EP3610215B1 EP 3610215 B1 EP3610215 B1 EP 3610215B1 EP 18720441 A EP18720441 A EP 18720441A EP 3610215 B1 EP3610215 B1 EP 3610215B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- finstock
- layers
- manifold
- center
- manifold structure
- Prior art date
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
- F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
- F28F21/081—Heat exchange elements made from metals or metal alloys
- F28F21/084—Heat exchange elements made from metals or metal alloys from aluminium or aluminium alloys
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
- B23K20/103—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding using a roller
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
- B23K20/106—Features related to sonotrodes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
- B23K20/233—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer
- B23K20/2336—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer both layers being aluminium
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/26—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass heat exchangers or the like
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D9/0081—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by a single plate-like element ; the conduits for one heat-exchange medium being integrated in one single plate-like element
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
- F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/02—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/02—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
- F28F3/04—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being integral with the element
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/02—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
- F28F3/04—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being integral with the element
- F28F3/048—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being integral with the element in the form of ribs integral with the element or local variations in thickness of the element, e.g. grooves, microchannels
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/02—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
- F28F3/06—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being attachable to the element
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/08—Elements constructed for building-up into stacks, e.g. capable of being taken apart for cleaning
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/12—Elements constructed in the shape of a hollow panel, e.g. with channels
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/20009—Modifications to facilitate cooling, ventilating, or heating using a gaseous coolant in electronic enclosures
- H05K7/20136—Forced ventilation, e.g. by fans
- H05K7/20154—Heat dissipaters coupled to components
- H05K7/20163—Heat dissipaters coupled to components the components being isolated from air flow, e.g. hollow heat sinks, wind tunnels or funnels
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/20218—Modifications to facilitate cooling, ventilating, or heating using a liquid coolant without phase change in electronic enclosures
- H05K7/20254—Cold plates transferring heat from heat source to coolant
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/04—Tubular or hollow articles
- B23K2101/14—Heat exchangers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/10—Aluminium or alloys thereof
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
- F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
- F28F21/081—Heat exchange elements made from metals or metal alloys
- F28F21/085—Heat exchange elements made from metals or metal alloys from copper or copper alloys
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2250/00—Arrangements for modifying the flow of the heat exchange media, e.g. flow guiding means; Particular flow patterns
- F28F2250/10—Particular pattern of flow of the heat exchange media
- F28F2250/106—Particular pattern of flow of the heat exchange media with cross flow
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
- F28F2255/06—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes composite, e.g. polymers with fillers or fibres
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2275/00—Fastening; Joining
- F28F2275/04—Fastening; Joining by brazing
Definitions
- the invention relates to structures manufactured using ultrasonic additive manufacturing, and more particularly, forming a part with more complex geometries using an ultrasonic additive manufacturing process and permanently joining the part to a brazed structure using a brazing or welding process for increasing thermal performance of the structure.
- the manifold structures may be in the form of heat exchangers of may include cold plates.
- cold plates may be used in applications having electronics that require cooling.
- cold plates and heat exchangers may be manufactured as brazed structure having pre-fabricated finstock that is dropped into a machined cavity of the brazed structure.
- brazing process may be disadvantageous in forming the finstock layers due to limitations in suitable materials and geometries of the finstock. For example, forming the finstock layers at angles greater than five degrees relative to a horizontal axis may not be possible due to spillage of the filler material used during brazing. Spillage of the filler material may result in failure of the brazed joints. Brazed finstock layers may also be limited in thickness in that thinner layers may be difficult to braze together and more prone to causing spillage of the filler material during brazing. Additionally, dissimilar metal materials may also be difficult to braze together due to varying melting temperatures that may not be suitable for brazing.
- US 2015/137412 A1 discloses an additive manufacturing process that is particularly useful in the production of compact heat exchangers, chemical reactors, static chemical mixers and recuperators.
- US 2015/007969 A1 discloses a heat exchanger including a pair of opposed, spaced apart heat exchanger plates defining a heat exchanger volume therebetween having an inlet and opposed outlet.
- a plurality of heat exchanger ribs are included within the heat exchanger volume.
- Each rib defines a rib body spanning the heat exchanger volume.
- Each rib body includes a plurality of slits therethrough to define a flow path through the heat exchanger ribs from the inlet to the outlet of the heat exchanger volume.
- the ribs and slits can be formed using ultrasonic additive manufacturing (UAM), for example.
- UAM ultrasonic additive manufacturing
- US 2015/352661 A1 discloses an assembly including a substrate having a top surface and an inner wall, the inner wall defining a cavity, and at least one metal foil layer ultrasonically welded to the substrate top surface using an ultrasonic additive manufacturing process.
- the at least one metal foil layer extends across the cavity to define a passage, and the at least one metal foil layer is substantially planar and is parallel to the substrate top surface.
- US 5 381 859 A discloses a heat sink comprising a multilayered body realized by laying a plurality of heat sink fin elements one upon the other to a multilayer structure with a spacer inserted between any two adjacent elements.
- a heat sink having such configuration is then rigidly fitted to a thermally conductive plate which is in contact with a heat transmission medium (e.g. water) or loaded with a heat source by soldering or other bonding technique in such a way that an outer surface of the multilayered body where the spacers are fully exposed faces the thermally conductive plate.
- the multilayered body may be arranged in an atmosphere of a flowing fluid coolant.
- a supporting body of a thermally conductive material is provided with a number of paired grooves for receiving lateral edges of heat sink fin elements.
- a multilayered body can be produced by bonding the heat sink fin elements to the supporting body with a bonding agent.
- Ultrasonic additive manufacturing is advantageous in forming a manifold structure, such as a heat exchanger or cold plates.
- a finned heat exchanger provides for more efficient heat transfer.
- UAM Ultrasonic additive manufacturing
- the manifold structure includes a center manifold section that is formed of a metal material and has at least one machined cavity or flow passage. After the finstock layers or finned cavity is formed by UAM, the finned cavity may be permanently joined to the center manifold section by way of a brazing or welding process.
- the resulting manifold structure has multi-material laminate materials comprising dissimilar metal materials that are integrated into the center manifold section.
- the resulting manifold structure may also have bond joints of the finstock layers that are arranged at angles greater than ten degrees relative to a horizontal axis, as compared with using only a brazing process which may result in spillage of the brazing filler material due to different melting points of the cast material and the brazed structure.
- a manifold structure has at least one flow passage, the manifold structure comprising: a center manifold section formed of a metal material and having at least one machined cavity in communication with the at least one flow passage; and a plurality of ultrasonic additively manufactured finstock layers that are arranged within the flow passage and segment the flow passage into a plurality of flow cavities; wherein the finstock layers are stacked in a direction normal to the center manifold section and permanently joined to the center manifold section; and wherein the finstock layers are formed of a multi-material laminate material comprising dissimilar metal materials that is integrated into the metal material of the center manifold section.
- the finstock layers may be welded or brazed to the center manifold section.
- the center manifold section may be formed of aluminum.
- the multi-material laminate material may include an aluminum material.
- the multi-material laminate material may further include at least one of copper, molybdenum, tungsten, titanium, or silicon carbide.
- the finstock layers may have bond joints that are arranged at angles greater than ten degrees relative to a horizontal axis.
- a manifold structure has at least one flow passage, the manifold structure comprising: a center manifold section that is formed of a metal material and has at least one machined cavity; and a plurality of ultrasonic additively manufactured finstock layers that are arranged within the flow passage and segment the flow passage into a plurality of flow cavities; wherein the finstock layers are stacked in a direction normal to the center manifold section and permanently joined to the center manifold section; and wherein the center manifold section extends along a horizontal axis, and at least one of the finstock layers has a bond joint that is arranged at an angle greater than ten degrees relative to the horizontal axis.
- the finstock layers may be formed of more than one metal material.
- the finstock layers may be formed of a multi-material laminate material.
- the center manifold section may be formed of aluminum.
- the finstock layers may be formed of aluminum and at least one second material that is embedded within the aluminum.
- the at least one second material may be copper, molybdenum, tungsten, titanium, or silicon carbide.
- the manifold structure may be a heat exchanger.
- the manifold structure may include at least one vacuum brazed cold plate.
- a method of forming a manifold structure is used to form a manifold structure having at least one flow passage, the method comprising: forming a plurality of finstock layers using an ultrasonic additive manufacturing process; forming a center manifold section of a metal material; machining the center manifold section to form at least one cavity; arranging the plurality of finstock layers within the at least one cavity of the center manifold section to segment the at least one cavity into a plurality of flow cavities; and permanently joining the plurality of finstock layers to the center manifold section; wherein the finstock layers are formed of a multi-material laminate material comprising dissimilar metal materials that is integrated into the metal material of the center manifold section.
- permanently joining the finstock layers to the center manifold section may include using a brazing process or a welding process.
- the method may further include forming the plurality of finstock layers of an aluminum material, and vacuum brazing the plurality of finstock layers to the center manifold section using a filler material that is formed of the aluminum material of the finstock layers.
- forming the plurality of finstock layers may include forming a first layer, wherein the first layer is formed of a first metal material, and embedding a second layer within the first layer for heat spreading, wherein the second layer is formed of a second metal material.
- forming the finstock layers may include arranging bond joints of the finstock layers at angles greater than ten degrees relative to a horizontal axis.
- the principles described herein have particular application in a manifold structure that may be used for heating or cooling a surface to which the manifold structure is attached.
- the manifold structure may be a heat exchanger.
- the manifold structure may include cold plates. Cold plates may be used in various applications, such as in military electronics packaging or in any suitable aerospace application for cooling electronics. For example, cold plates may be implemented in radar structures.
- the manifold structure described herein may be implemented in many other applications. For example, the manifold structure may be used in lightweight armor.
- UAM is advantageous in forming manifold structures or parts of manifold structures due to the capabilities of UAM in producing complex internal features within metallic materials.
- Examples of complex internal features that may be formed by UAM include honeycomb structures, internal pipes or channels, and enclosed cavities.
- UAM may be advantageous in forming finstock of the manifold structure.
- the UAM finstock may then be permanently joined to a machined metal part of the manifold structure via a brazing process or a welding process.
- the manifold structure may be finned for more efficient heat transfer through the manifold structure, by way of convection across the finstock.
- the finstock may be sheet-like in shape.
- UAM to build up layers of finstock for a cavity or flow passage of the manifold structure allows the layers or sheets of finstock to be stacked in a direction normal to the direction of fluid flow through a corresponding flow passage of the manifold structure.
- the finstock may also be oriented in a direction normal to the surface to be heated or cooled.
- the arrangement of the finstock provides more efficient heat transfer through the manifold structure as compared with conventional manifold structures that have vertically-arranged finstock.
- the manifold structure 20 has a length 22 that extends along a horizontal or x-axis, a height 24 that extends along a vertical or y-axis, and a width 26 that extends perpendicularly to the horizontal axis and the vertical axis, or along a z-axis.
- the length 22 may be greater than the height 24 and the width 26.
- the length 22, height 24, and the width 26 of the manifold structure may be dependent on the application.
- the manifold structure 20 may have a length 22 of around 50 centimeters (20 inches), although many other lengths are possible.
- the manifold structure 20 includes at least one flow passage that extends along the length 22 or the width 26 of the manifold structure 20.
- the manifold structure 20 may include a plurality of flow passages.
- the manifold structure 20 includes a main body part, such as a center manifold 28.
- the center manifold 28 may be formed of metal by any suitable metal forming process.
- the center manifold 28 is formed of any suitable metal material, such as aluminum.
- the center manifold 28 may be formed by a milling, machining, and stamping process.
- the center manifold 28 may be formed of 6000-series aluminum.
- the center manifold 28 may be rectangular or plate-like in shape and is elongated along the length 22 of the manifold structure 20.
- the center manifold 28 has at least one machined cavity or channel that extends along the length 22 or the width 26 of the manifold structure 20.
- the height and the width of the center manifold 28 may be less than the length of the center manifold 28 and the height may be less than the width. Fluid may flow through the structure 20 by way of the cavity or channel.
- the manifold structure 20 may include at least one unit cell 30 that is permanently adjoined to the center manifold 28.
- the manifold structure 20 may include a plurality of unit cells that are adjoined to a top surface 32 of the center manifold 28 and a plurality of unit cells that are permanently joined to a bottom surface 34 of the center manifold 28.
- the unit cells may extend vertically from the center manifold 28 and may be arranged horizontally along the center manifold 28.
- the unit cells that are arranged on a corresponding side of the center manifold 28 may be spaced by a gap 36.
- Each unit cell 30 may include flow passages that contain finstock 38.
- the finstock 38 may be provided for structural integrity of the manifold structure 20 and providing an extended surface area for heat transfer through the flow passages of the manifold structure 20.
- the finstock 38 may be generally square-shaped.
- the finstock 38 may be relatively thin and in an exemplary embodiment, the finstock 38 may have a thickness between 0.0025 centimeters (0.0010 inches) and 0.0381 centimeters (0.0150 inches).
- the fin sheets or finstock 38 is arranged in vertical stacks 40 relative to a flow direction 42 of heat travel through the manifold structure 20.
- the flow direction 42 may be in the direction of the z-axis or width 26 of the manifold structure 20.
- Each unit cell 30 may include a plurality of vertical stacks 40 of finstock 38.
- the vertical stacks 40 may be spaced in both a horizontal and vertical direction such that the stacks 40 form a plurality of rows and columns of finstock 38.
- the manifold structure 20 may include six unit cells and each unit cell 30 may include six stacks of finstock 38.
- Each unit cell 30 may further include internal layers 44 that are disposed between rows of the vertical stacks 40 of finstock 38.
- the internal layers 44 may extend along the length 22 of each unit cell 30.
- the internal layers 44 may be used for enhanced heat spreading through the flow passage of the manifold structure 20.
- each unit cell 30 may include three internal layers that separate two rows of vertical stacks 40 of finstock 38.
- the finstock 38 may be interposed between flat metal separator plates 48.
- the sheets of finstock 38 are arranged horizontally, or in a direction normal to the direction of heat flow through the manifold structure 20, providing for a shorter and more direct path of heat travel relative to the heat travel path of the prior art where the finstock is arranged vertically.
- the finstock 38 may be arranged in a direction normal to the surface to be heated or cooled (not shown).
- the flow passages of the manifold structure 20 may extend in a longitudinal direction and in a transverse direction.
- the layers of finstock 38 may extend through the flow passages and define cavities 46 between each layer to enable flow through the respective flow passage.
- the flow passage may be segmented by the finstock 38 such that each cavity 46 forms a sub-flow passage through the larger flow passage.
- the sub-flow passages may extend in the flow direction 42, or along the width 26 of the manifold structure 20.
- the finstock 38 may have bond joints which may be defined as the points of contact between the sheets of finstock 38 and vertically extending support walls of the corresponding unit cell 30.
- the finstock 38 is configured to increase heat transfer from the heated surface to which the manifold structure 20 is attached, via the surface area of the finstock 38.
- the finstock 38 enables heat flow through the manifold structure 20 by way of convection.
- the finstock 38 accommodates for reduction in temperature potential between the finstock 38 and the ambient fluid due to conduction along the finstock 38 and convection from or to the surface of the finstock 38.
- the fin efficiency is dependent on fin geometry, fin material thermal conductivity, and a heat transfer coefficient at the fin surface. Arranging the finstock 38 normal to the surface effectively changes the geometry of the fin, by providing a more direct heat transfer path through the heat exchanger.
- an exemplary configuration of the manifold structure may be a cold plate structure 48 used for military electronics packaging.
- the cold plate structure 48 may include a plurality of machined aluminum plates 48a, 48b that are vertically stacked.
- the plate 48b may have at least one milled channel 50 that extends along the length of the plate 48b.
- the plate 48b may also have a milled recess 52 that is in communication with the milled channel 50 for receiving layers of finstock 38 that segment the flow passage into a plurality of flow passages.
- the finstock 38 may be pre-manufactured and permanently joined into the milled recess 52.
- the finstock 38 is formed by ultrasonic additive manufacturing.
- UAM Using UAM to form the finstock 38 may be advantageous in that UAM enables the finstock 38 to be formed of a multi-material laminate material comprising dissimilar metal materials, as compared with conventional manifold structures that are limited to a single material due to different melting temperatures of materials at brazing temperatures. Furthermore, the finstock 38 formed of UAM may also be advantageous in that the bond joints of the finstock 38 may be arranged at off-angle geometries, such as angles greater than ten degrees relative to the horizontal axis ( Fig. 1 ).
- top and bottom sections of the manifold structure may be machined as shells and the finstock may be laser trimmed to fit into each shell with braze material.
- brazing the finstock layers into the cavities of the manifold structure may be disadvantageous due to the restraint of the geometries of the finstock layers.
- Using conventional method to form the finstock layers may prevent the finstock layers from being angled more than five or ten degrees relative to the horizontal axis due to gravity and spillage of the filler material at the temperatures required for brazing. Spillage of the filler material may result in finstock layers being offset or non-uniformly formed.
- joining additive manufactured aluminum parts using laser powder bed fusion may produce an aluminum material having a melting temperature that is too low to withstand the 6000-series aluminum material that is used in standard vacuum brazes.
- UAM enables the aluminum plates 48a, 48b to be formed of a 6000-series aluminum and the finstock material to be formed of 1100-series aluminum that has a lower melting temperature as compared with the 6000-series aluminum.
- Brazed finstock that is formed of a metal other than the base metal of the structure may also cause the yield strength of the brazed finstock to be less than that of the base metal. The lesser yield strength of the brazed finstock may result in bowing or deformation of the brazed finstock layers formed over the cavity.
- UAM Using UAM enables finstock formed of multi-material laminate materials comprising dissimilar metal materials to be permanently joined to the cold plates as compared with using the conventional brazing process during which the 1100-series aluminum would spill out of the milled recess 52.
- Forming the finstock by UAM enables material properties of the base material of the finstock to be maintained.
- UAM enables forming the finstock by welding of multi-material laminate materials comprising dissimilar metal materials, such that multiple metal foils may be combined.
- Materials that may be suitable for forming the finstock using UAM include aluminum, copper, molybdenum, tungsten, titanium, and silicon carbide. Many other materials may be suitable.
- suitable metal materials for the UAM process may include beryllium, gold, iron, nickel, platinum, tantalum, and zirconium. Alloys of aluminum, copper, gold, iron, nickel and platinum may also be suitable.
- the material may include a ceramic-fiber reinforced metal matrix material. It should be recognized that the maximum width of a cavity in the part may be dependent on the material of the part. For example, the maximum width of an unsupported cavity in an H18 aluminum part may be between 0.508 centimeters (0.200 inches) and 0.609 centimeters (0.240 inches) due to lower tensile strengths and hardness properties as compared with other aluminum alloys.
- aluminum alloys or other materials having tensile strengths between 130 and 390 megapascals or a Brinell hardness number greater than 35 may be suitable.
- an aluminum alloy such as 6061-T6 may be used.
- Multi-material laminates are formed of dissimilar metal materials and integrated into an aluminum brazement of the manifold structure.
- suitable multi-material laminates for the finstock may include a laminate formed of copper and molybdenum, copper and aluminum, copper and tungsten, or aluminum and silicon carbide.
- UAM may be used to integrate a silicon carbide material 54 into an aluminum base material 56.
- a copper material 58 may be used as the internal layer or heat spreading layer 44 ( Fig. 1 ). Many other materials may be suitable for forming the heat spreading layer.
- Fig. 4 is a flow chart illustrating a method 60 of forming the manifold structure 20.
- Figs. 5-7 are schematic drawings illustrating the system used to form the manifold structure 20.
- the method 60 includes using UAM to build the layers of finstock 38 ( Fig. 1 ).
- Fig. 5 is a schematic drawing of a UAM machine 72. The UAM process is used to build up the finstock 38 or finned cavities on a base plate 74 that is an existing part or a portion of an existing structure.
- the base plate 74 may be a heated substrate having a temperature in a range from near ambient room temperature up to 200 degrees Celsius.
- the UAM machine 72 includes a rotatable sonotrode 76 that travels along a length of a thin metal foil, or tape 78.
- the tape 78 may have a width between 100 and 150 microns and a thickness between 1.25 centimeters (0.5 inches) and 3.80 centimeters (1.5 inches).
- the sonotrode 76 is used to apply a force normal to the tape 78 to hold the tape 78 to the base plate 74 or another tape.
- the method 60 of forming the manifold structure 20 includes forming the plurality of layers of finstock 38 ( Fig. 1 ) using ultrasonic additive manufacturing process. Forming the plurality of layers of finstock 38 includes using multi-material laminate materials comprising dissimilar metal materials.
- step 80 of the method 60 includes laying the tapes 78 side-by-side to form a tape layer. Step 80 is repeated to form a plurality of tape layers.
- Step 80 may include forming a first layer ( Fig. 3 ) of a first metal material 56 ( Fig. 3 ), such as aluminum, and embedding a second layer ( Fig. 3 ) of a second metal material 58, such as copper, within the first layer.
- the second metal material may be used as a heat spreading material for enhanced thermal properties of the part.
- step 82 includes staggering the tape layers to form a homogenous structure that does not contain gaps between the tapes. The process may be repeated to form each of the layers of finstock 38 and cavities 46 ( Fig. 1 ) between the layers. Step 82 may further include arranging the finstock layers at angles greater than ten degrees relative to the horizontal axis of the manifold structure 20. Referring in addition to Fig. 6 , a schematic drawing of the merging or welding of tape layers 84, 86 is shown.
- the sonotrode 76 may include transducers 88 that produce vibrations to oscillate the sonotrode 76 transversely to the direction of rotation of the sonotrode 76.
- the sonotrode 76 may oscillate at a constant frequency, around 20 kilohertz, to break oxide layers on the tapes of the tape layers 84, 86 to be adjoined to form a bonded or welded tape 90.
- Fig. 7 shows the tapes 78 laid side-by-side to form the layers 84, 86.
- the layers 84, 86 are stacked such that the tapes 78 of each layer are staggered.
- Each layer is welded or merged to a previously formed layer, such that the homogeneous structure 92 is formed by building up the layers.
- step 94 includes forming the center manifold section 28 ( Fig. 1 ) of a metal material.
- Step 94 may include any suitable metal forming process and may include milling and stamping.
- step 96 of the method 60 includes further machining the center manifold section 28 to form at least one cavity 50 ( Fig. 2 ), milled recess 52 ( Fig. 2 ) or other flow passages.
- the cavity may be formed by computer numerical control (CNC) machining or milling.
- CNC machining may be used to mill or trim the upward-facing surface of the plate 48b ( Fig. 2 ) to form the cavity 52 ( Fig. 2 ).
- the CNC machining may include using a conical tool or a ball nose cutter to vertically mill into the plate 48b.
- step 98 of the method 60 includes permanently joining the plurality of layers of finstock 38 to the center manifold section 28.
- the finstock 38 is arranged within the machined cavity of the center manifold section 28 to segment the cavity into a plurality of flow cavities.
- Permanently joining the layers of finstock 38 to the center manifold section 28 may include using a vacuum brazing process or a welding process.
- UAM and the vacuum brazing process may use the same 6000-series aluminum material. Other permanent joining processes may be suitable depending on the melting points of the materials used. Using both a UAM process and a brazing process enables more complex parts to be created using UAM and combined in a lower cost brazing process to form the manifold structure.
- the finstock layers are arranged to optimize heat transfer through the manifold structure, such as in a direction normal to the heated surface.
- Increasing efficiency of the cooling function performed by the manifold structure allows for improved thermal performance of manifold structures used for cooling high power electronics.
- Applications requiring cooling manifolds may implement fewer manifolds, given the increased efficiency of the manifold structure according to the present application.
- Providing fewer manifold structures decreases power used to pump coolant through the manifolds, effectively reducing the overall operating costs of the electronics and associated cooling manifold structure.
- the manifold structure according to the present application may be implemented to allow radars to operate at a higher energy level due to the improved detection of the radar by increased efficiency of cooling the circuitry.
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Description
- The invention relates to structures manufactured using ultrasonic additive manufacturing, and more particularly, forming a part with more complex geometries using an ultrasonic additive manufacturing process and permanently joining the part to a brazed structure using a brazing or welding process for increasing thermal performance of the structure.
- Many applications use heating or cooling manifold structures that include sheet-like finstock layers for more efficient heat transfer through the manifold structure by way of convection across the finstock. The manifold structures may be in the form of heat exchangers of may include cold plates. For example, cold plates may be used in applications having electronics that require cooling. Conventionally, cold plates and heat exchangers may be manufactured as brazed structure having pre-fabricated finstock that is dropped into a machined cavity of the brazed structure.
- However, using a brazing process may be disadvantageous in forming the finstock layers due to limitations in suitable materials and geometries of the finstock. For example, forming the finstock layers at angles greater than five degrees relative to a horizontal axis may not be possible due to spillage of the filler material used during brazing. Spillage of the filler material may result in failure of the brazed joints. Brazed finstock layers may also be limited in thickness in that thinner layers may be difficult to braze together and more prone to causing spillage of the filler material during brazing. Additionally, dissimilar metal materials may also be difficult to braze together due to varying melting temperatures that may not be suitable for brazing.
- Attempts have been made to join casted parts having enhanced thermal features to vacuum brazements. For example, laser powder bed fusion using powder aluminum has been previously used. However, using powder aluminum may be disadvantageous due to different melting points of the cast aluminum and the brazement. For example, the laser powder bed fusion results in a cast aluminum having a melting temperature that is too low to withstand a standard vacuum braze process that uses 6000-series aluminum.
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US 2015/137412 A1 discloses an additive manufacturing process that is particularly useful in the production of compact heat exchangers, chemical reactors, static chemical mixers and recuperators. -
US 2015/007969 A1 discloses a heat exchanger including a pair of opposed, spaced apart heat exchanger plates defining a heat exchanger volume therebetween having an inlet and opposed outlet. A plurality of heat exchanger ribs are included within the heat exchanger volume. Each rib defines a rib body spanning the heat exchanger volume. Each rib body includes a plurality of slits therethrough to define a flow path through the heat exchanger ribs from the inlet to the outlet of the heat exchanger volume. The ribs and slits can be formed using ultrasonic additive manufacturing (UAM), for example. -
US 2015/352661 A1 discloses an assembly including a substrate having a top surface and an inner wall, the inner wall defining a cavity, and at least one metal foil layer ultrasonically welded to the substrate top surface using an ultrasonic additive manufacturing process. The at least one metal foil layer extends across the cavity to define a passage, and the at least one metal foil layer is substantially planar and is parallel to the substrate top surface. -
US 5 381 859 A discloses a heat sink comprising a multilayered body realized by laying a plurality of heat sink fin elements one upon the other to a multilayer structure with a spacer inserted between any two adjacent elements. A heat sink having such configuration is then rigidly fitted to a thermally conductive plate which is in contact with a heat transmission medium (e.g. water) or loaded with a heat source by soldering or other bonding technique in such a way that an outer surface of the multilayered body where the spacers are fully exposed faces the thermally conductive plate. The multilayered body may be arranged in an atmosphere of a flowing fluid coolant. In an embodiment, a supporting body of a thermally conductive material is provided with a number of paired grooves for receiving lateral edges of heat sink fin elements. A multilayered body can be produced by bonding the heat sink fin elements to the supporting body with a bonding agent. - Ultrasonic additive manufacturing (UAM) is advantageous in forming a manifold structure, such as a heat exchanger or cold plates. A finned heat exchanger provides for more efficient heat transfer. Using UAM to build up layers of finstock enables the finstock to have more complex geometries within the manifold structure. The manifold structure includes a center manifold section that is formed of a metal material and has at least one machined cavity or flow passage. After the finstock layers or finned cavity is formed by UAM, the finned cavity may be permanently joined to the center manifold section by way of a brazing or welding process. Using UAM to form the finstock layers and permanently joining the finstock layers to the center manifold section enables the joining of a casted part with enhanced thermal features to a vacuum brazed structure. The resulting manifold structure has multi-material laminate materials comprising dissimilar metal materials that are integrated into the center manifold section. The resulting manifold structure may also have bond joints of the finstock layers that are arranged at angles greater than ten degrees relative to a horizontal axis, as compared with using only a brazing process which may result in spillage of the brazing filler material due to different melting points of the cast material and the brazed structure.
- The following aspects of the invention may be combinable in any combination.
- According to an aspect of the invention, a manifold structure has at least one flow passage, the manifold structure comprising: a center manifold section formed of a metal material and having at least one machined cavity in communication with the at least one flow passage; and a plurality of ultrasonic additively manufactured finstock layers that are arranged within the flow passage and segment the flow passage into a plurality of flow cavities; wherein the finstock layers are stacked in a direction normal to the center manifold section and permanently joined to the center manifold section; and wherein the finstock layers are formed of a multi-material laminate material comprising dissimilar metal materials that is integrated into the metal material of the center manifold section.
- According to an aspect of the invention, the finstock layers may be welded or brazed to the center manifold section.
- According to an aspect of the invention, the center manifold section may be formed of aluminum.
- According to an aspect of the invention, the multi-material laminate material may include an aluminum material.
- According to an aspect of the invention, the multi-material laminate material may further include at least one of copper, molybdenum, tungsten, titanium, or silicon carbide.
- According to an aspect of the invention, the finstock layers may have bond joints that are arranged at angles greater than ten degrees relative to a horizontal axis.
- According to an aspect of the invention, a manifold structure has at least one flow passage, the manifold structure comprising: a center manifold section that is formed of a metal material and has at least one machined cavity; and a plurality of ultrasonic additively manufactured finstock layers that are arranged within the flow passage and segment the flow passage into a plurality of flow cavities; wherein the finstock layers are stacked in a direction normal to the center manifold section and permanently joined to the center manifold section; and wherein the center manifold section extends along a horizontal axis, and at least one of the finstock layers has a bond joint that is arranged at an angle greater than ten degrees relative to the horizontal axis.
- According to an aspect of the invention, the finstock layers may be formed of more than one metal material.
- According to an aspect of the invention, the finstock layers may be formed of a multi-material laminate material.
- According to an aspect of the invention, the center manifold section may be formed of aluminum.
- According to an aspect of the invention, the finstock layers may be formed of aluminum and at least one second material that is embedded within the aluminum.
- According to an aspect of the invention, the at least one second material may be copper, molybdenum, tungsten, titanium, or silicon carbide.
- According to an aspect of the invention, the manifold structure may be a heat exchanger.
- According to an aspect of the invention, the manifold structure may include at least one vacuum brazed cold plate.
- According to an aspect of the invention, a method of forming a manifold structure is used to form a manifold structure having at least one flow passage, the method comprising: forming a plurality of finstock layers using an ultrasonic additive manufacturing process; forming a center manifold section of a metal material; machining the center manifold section to form at least one cavity; arranging the plurality of finstock layers within the at least one cavity of the center manifold section to segment the at least one cavity into a plurality of flow cavities; and permanently joining the plurality of finstock layers to the center manifold section; wherein the the finstock layers are formed of a multi-material laminate material comprising dissimilar metal materials that is integrated into the metal material of the center manifold section.
- According to an aspect of the invention, permanently joining the finstock layers to the center manifold section may include using a brazing process or a welding process.
- According to an aspect of the invention, the method may further include forming the plurality of finstock layers of an aluminum material, and vacuum brazing the plurality of finstock layers to the center manifold section using a filler material that is formed of the aluminum material of the finstock layers.
- According to an aspect of the invention, forming the plurality of finstock layers may include forming a first layer, wherein the first layer is formed of a first metal material, and embedding a second layer within the first layer for heat spreading, wherein the second layer is formed of a second metal material.
- According to an aspect of the invention, forming the finstock layers may include arranging bond joints of the finstock layers at angles greater than ten degrees relative to a horizontal axis.
- To the accomplishment of the foregoing and related ends, the invention comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of the invention. These embodiments are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.
- The annexed drawings, which are not necessarily to scale, show various aspects of the invention.
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Fig. 1 is a schematic drawing showing an oblique view of a manifold structure. -
Fig. 2 is a drawing showing an oblique view of a cold plate having finstock. -
Fig. 3 is a drawing showing a scanning electronic microscope image of a part formed by an ultrasonic additive manufacturing (UAM) process. -
Fig. 4 is a flow chart illustrating a method of forming the manifold structure ofFig. 1 . -
Fig. 5 is a schematic drawing showing an oblique view of a system for performing a UAM process. -
Fig. 6 is a schematic drawing showing an oblique view of metal tape layers that are merged together during the UAM process. -
Fig. 7 is a schematic drawing showing a build-up of tape layers during the UAM process. - The principles described herein have particular application in a manifold structure that may be used for heating or cooling a surface to which the manifold structure is attached. The manifold structure may be a heat exchanger. The manifold structure may include cold plates. Cold plates may be used in various applications, such as in military electronics packaging or in any suitable aerospace application for cooling electronics. For example, cold plates may be implemented in radar structures. The manifold structure described herein may be implemented in many other applications. For example, the manifold structure may be used in lightweight armor.
- UAM is advantageous in forming manifold structures or parts of manifold structures due to the capabilities of UAM in producing complex internal features within metallic materials. Examples of complex internal features that may be formed by UAM include honeycomb structures, internal pipes or channels, and enclosed cavities. UAM may be advantageous in forming finstock of the manifold structure. The UAM finstock may then be permanently joined to a machined metal part of the manifold structure via a brazing process or a welding process. The manifold structure may be finned for more efficient heat transfer through the manifold structure, by way of convection across the finstock. The finstock may be sheet-like in shape. Using UAM to build up layers of finstock for a cavity or flow passage of the manifold structure allows the layers or sheets of finstock to be stacked in a direction normal to the direction of fluid flow through a corresponding flow passage of the manifold structure. The finstock may also be oriented in a direction normal to the surface to be heated or cooled. The arrangement of the finstock provides more efficient heat transfer through the manifold structure as compared with conventional manifold structures that have vertically-arranged finstock.
- Referring now to
Fig. 1 , anexemplary manifold structure 20 is schematically shown. Themanifold structure 20 has alength 22 that extends along a horizontal or x-axis, aheight 24 that extends along a vertical or y-axis, and awidth 26 that extends perpendicularly to the horizontal axis and the vertical axis, or along a z-axis. Thelength 22 may be greater than theheight 24 and thewidth 26. Thelength 22,height 24, and thewidth 26 of the manifold structure may be dependent on the application. In an exemplary configuration, themanifold structure 20 may have alength 22 of around 50 centimeters (20 inches), although many other lengths are possible. Themanifold structure 20 includes at least one flow passage that extends along thelength 22 or thewidth 26 of themanifold structure 20. Themanifold structure 20 may include a plurality of flow passages. - The
manifold structure 20 includes a main body part, such as acenter manifold 28. Thecenter manifold 28 may be formed of metal by any suitable metal forming process. Thecenter manifold 28 is formed of any suitable metal material, such as aluminum. Thecenter manifold 28 may be formed by a milling, machining, and stamping process. In an exemplary embodiment, thecenter manifold 28 may be formed of 6000-series aluminum. Thecenter manifold 28 may be rectangular or plate-like in shape and is elongated along thelength 22 of themanifold structure 20. Thecenter manifold 28 has at least one machined cavity or channel that extends along thelength 22 or thewidth 26 of themanifold structure 20. The height and the width of thecenter manifold 28 may be less than the length of thecenter manifold 28 and the height may be less than the width. Fluid may flow through thestructure 20 by way of the cavity or channel. - The
manifold structure 20 may include at least oneunit cell 30 that is permanently adjoined to thecenter manifold 28. Themanifold structure 20 may include a plurality of unit cells that are adjoined to atop surface 32 of thecenter manifold 28 and a plurality of unit cells that are permanently joined to abottom surface 34 of thecenter manifold 28. The unit cells may extend vertically from thecenter manifold 28 and may be arranged horizontally along thecenter manifold 28. The unit cells that are arranged on a corresponding side of thecenter manifold 28 may be spaced by agap 36. Eachunit cell 30 may include flow passages that containfinstock 38. Thefinstock 38 may be provided for structural integrity of themanifold structure 20 and providing an extended surface area for heat transfer through the flow passages of themanifold structure 20. Thefinstock 38 may be generally square-shaped. Thefinstock 38 may be relatively thin and in an exemplary embodiment, thefinstock 38 may have a thickness between 0.0025 centimeters (0.0010 inches) and 0.0381 centimeters (0.0150 inches). The fin sheets orfinstock 38 is arranged invertical stacks 40 relative to aflow direction 42 of heat travel through themanifold structure 20. Theflow direction 42 may be in the direction of the z-axis orwidth 26 of themanifold structure 20. - Each
unit cell 30 may include a plurality ofvertical stacks 40 offinstock 38. Thevertical stacks 40 may be spaced in both a horizontal and vertical direction such that thestacks 40 form a plurality of rows and columns offinstock 38. As shown in the exemplary configuration ofFig. 1 , themanifold structure 20 may include six unit cells and eachunit cell 30 may include six stacks offinstock 38. Eachunit cell 30 may further includeinternal layers 44 that are disposed between rows of thevertical stacks 40 offinstock 38. Theinternal layers 44 may extend along thelength 22 of eachunit cell 30. Theinternal layers 44 may be used for enhanced heat spreading through the flow passage of themanifold structure 20. For example, eachunit cell 30 may include three internal layers that separate two rows ofvertical stacks 40 offinstock 38. - The
finstock 38 may be interposed between flatmetal separator plates 48. The sheets offinstock 38 are arranged horizontally, or in a direction normal to the direction of heat flow through themanifold structure 20, providing for a shorter and more direct path of heat travel relative to the heat travel path of the prior art where the finstock is arranged vertically. Thefinstock 38 may be arranged in a direction normal to the surface to be heated or cooled (not shown). The flow passages of themanifold structure 20 may extend in a longitudinal direction and in a transverse direction. The layers offinstock 38 may extend through the flow passages and definecavities 46 between each layer to enable flow through the respective flow passage. The flow passage may be segmented by thefinstock 38 such that eachcavity 46 forms a sub-flow passage through the larger flow passage. As shown inFig. 1 , the sub-flow passages may extend in theflow direction 42, or along thewidth 26 of themanifold structure 20. Thefinstock 38 may have bond joints which may be defined as the points of contact between the sheets offinstock 38 and vertically extending support walls of thecorresponding unit cell 30. - In an exemplary configuration where the manifold structure is a heat exchanger, the
finstock 38 is configured to increase heat transfer from the heated surface to which themanifold structure 20 is attached, via the surface area of thefinstock 38. Thefinstock 38 enables heat flow through themanifold structure 20 by way of convection. Thefinstock 38 accommodates for reduction in temperature potential between the finstock 38 and the ambient fluid due to conduction along thefinstock 38 and convection from or to the surface of thefinstock 38. The fin efficiency is dependent on fin geometry, fin material thermal conductivity, and a heat transfer coefficient at the fin surface. Arranging thefinstock 38 normal to the surface effectively changes the geometry of the fin, by providing a more direct heat transfer path through the heat exchanger. - Referring in addition to
Fig. 2 , an exemplary configuration of the manifold structure may be acold plate structure 48 used for military electronics packaging. Thecold plate structure 48 may include a plurality of machinedaluminum plates plate 48b may have at least one milledchannel 50 that extends along the length of theplate 48b. Theplate 48b may also have a milledrecess 52 that is in communication with the milledchannel 50 for receiving layers offinstock 38 that segment the flow passage into a plurality of flow passages. Thefinstock 38 may be pre-manufactured and permanently joined into the milledrecess 52. Thefinstock 38 is formed by ultrasonic additive manufacturing. Using UAM to form thefinstock 38 may be advantageous in that UAM enables thefinstock 38 to be formed of a multi-material laminate material comprising dissimilar metal materials, as compared with conventional manifold structures that are limited to a single material due to different melting temperatures of materials at brazing temperatures. Furthermore, thefinstock 38 formed of UAM may also be advantageous in that the bond joints of thefinstock 38 may be arranged at off-angle geometries, such as angles greater than ten degrees relative to the horizontal axis (Fig. 1 ). - Conventionally, top and bottom sections of the manifold structure may be machined as shells and the finstock may be laser trimmed to fit into each shell with braze material. However, brazing the finstock layers into the cavities of the manifold structure may be disadvantageous due to the restraint of the geometries of the finstock layers. Using conventional method to form the finstock layers may prevent the finstock layers from being angled more than five or ten degrees relative to the horizontal axis due to gravity and spillage of the filler material at the temperatures required for brazing. Spillage of the filler material may result in finstock layers being offset or non-uniformly formed. For example, joining additive manufactured aluminum parts using laser powder bed fusion may produce an aluminum material having a melting temperature that is too low to withstand the 6000-series aluminum material that is used in standard vacuum brazes. In contrast, for example, UAM enables the
aluminum plates - Using UAM enables finstock formed of multi-material laminate materials comprising dissimilar metal materials to be permanently joined to the cold plates as compared with using the conventional brazing process during which the 1100-series aluminum would spill out of the milled
recess 52. Forming the finstock by UAM enables material properties of the base material of the finstock to be maintained. UAM enables forming the finstock by welding of multi-material laminate materials comprising dissimilar metal materials, such that multiple metal foils may be combined. Materials that may be suitable for forming the finstock using UAM include aluminum, copper, molybdenum, tungsten, titanium, and silicon carbide. Many other materials may be suitable. Other suitable metal materials for the UAM process may include beryllium, gold, iron, nickel, platinum, tantalum, and zirconium. Alloys of aluminum, copper, gold, iron, nickel and platinum may also be suitable. The material may include a ceramic-fiber reinforced metal matrix material. It should be recognized that the maximum width of a cavity in the part may be dependent on the material of the part. For example, the maximum width of an unsupported cavity in an H18 aluminum part may be between 0.508 centimeters (0.200 inches) and 0.609 centimeters (0.240 inches) due to lower tensile strengths and hardness properties as compared with other aluminum alloys. For increasing the maximum width of the unsupported cavity to greater than 0.635 centimeters (0.250 inches), aluminum alloys or other materials having tensile strengths between 130 and 390 megapascals or a Brinell hardness number greater than 35 may be suitable. In an exemplary embodiment, an aluminum alloy such as 6061-T6 may be used. - Multi-material laminates are formed of dissimilar metal materials and integrated into an aluminum brazement of the manifold structure. For example, suitable multi-material laminates for the finstock may include a laminate formed of copper and molybdenum, copper and aluminum, copper and tungsten, or aluminum and silicon carbide. With reference to
Fig. 3 which shows a scanning electron microscope image of a multi-material laminate used for the finstock 38 (Fig. 1 ) of the manifold structure, UAM may be used to integrate asilicon carbide material 54 into analuminum base material 56. As also shown inFig. 3 , acopper material 58 may be used as the internal layer or heat spreading layer 44 (Fig. 1 ). Many other materials may be suitable for forming the heat spreading layer. - Referring in addition to
Figs. 4-7 , a method and system for forming the manifold structure 20 (Fig. 1 ) are schematically illustrated.Fig. 4 is a flow chart illustrating amethod 60 of forming themanifold structure 20.Figs. 5-7 are schematic drawings illustrating the system used to form themanifold structure 20. Themethod 60 includes using UAM to build the layers of finstock 38 (Fig. 1 ).Fig. 5 is a schematic drawing of aUAM machine 72. The UAM process is used to build up thefinstock 38 or finned cavities on abase plate 74 that is an existing part or a portion of an existing structure. Thebase plate 74 may be a heated substrate having a temperature in a range from near ambient room temperature up to 200 degrees Celsius. TheUAM machine 72 includes arotatable sonotrode 76 that travels along a length of a thin metal foil, ortape 78. Thetape 78 may have a width between 100 and 150 microns and a thickness between 1.25 centimeters (0.5 inches) and 3.80 centimeters (1.5 inches). Thesonotrode 76 is used to apply a force normal to thetape 78 to hold thetape 78 to thebase plate 74 or another tape. - The
method 60 of forming the manifold structure 20 (Fig. 1 ) includes forming the plurality of layers of finstock 38 (Fig. 1 ) using ultrasonic additive manufacturing process. Forming the plurality of layers offinstock 38 includes using multi-material laminate materials comprising dissimilar metal materials. In an exemplary UAM process, step 80 of themethod 60 includes laying thetapes 78 side-by-side to form a tape layer.Step 80 is repeated to form a plurality of tape layers.Step 80 may include forming a first layer (Fig. 3 ) of a first metal material 56 (Fig. 3 ), such as aluminum, and embedding a second layer (Fig. 3 ) of asecond metal material 58, such as copper, within the first layer. The second metal material may be used as a heat spreading material for enhanced thermal properties of the part. - After a tape layer is formed,
step 82 includes staggering the tape layers to form a homogenous structure that does not contain gaps between the tapes. The process may be repeated to form each of the layers offinstock 38 and cavities 46 (Fig. 1 ) between the layers.Step 82 may further include arranging the finstock layers at angles greater than ten degrees relative to the horizontal axis of themanifold structure 20. Referring in addition toFig. 6 , a schematic drawing of the merging or welding of tape layers 84, 86 is shown. Thesonotrode 76 may include transducers 88 that produce vibrations to oscillate thesonotrode 76 transversely to the direction of rotation of thesonotrode 76. Thesonotrode 76 may oscillate at a constant frequency, around 20 kilohertz, to break oxide layers on the tapes of the tape layers 84, 86 to be adjoined to form a bonded or weldedtape 90.Fig. 7 shows thetapes 78 laid side-by-side to form thelayers layers tapes 78 of each layer are staggered. Each layer is welded or merged to a previously formed layer, such that thehomogeneous structure 92 is formed by building up the layers. - Before or after the homogeneous part or
solid structure 92 is formed by the UAM process, step 94 includes forming the center manifold section 28 (Fig. 1 ) of a metal material.Step 94 may include any suitable metal forming process and may include milling and stamping. After thecenter manifold section 28 is formed, step 96 of themethod 60 includes further machining thecenter manifold section 28 to form at least one cavity 50 (Fig. 2 ), milled recess 52 (Fig. 2 ) or other flow passages. The cavity may be formed by computer numerical control (CNC) machining or milling. CNC machining may be used to mill or trim the upward-facing surface of theplate 48b (Fig. 2 ) to form the cavity 52 (Fig. 2 ). The CNC machining may include using a conical tool or a ball nose cutter to vertically mill into theplate 48b. - After the
center manifold section 28 is formed, step 98 of themethod 60 includes permanently joining the plurality of layers offinstock 38 to thecenter manifold section 28. Before the layers offinstock 38 are permanently joined to thecenter manifold section 28, thefinstock 38 is arranged within the machined cavity of thecenter manifold section 28 to segment the cavity into a plurality of flow cavities. Permanently joining the layers offinstock 38 to thecenter manifold section 28 may include using a vacuum brazing process or a welding process. UAM and the vacuum brazing process may use the same 6000-series aluminum material. Other permanent joining processes may be suitable depending on the melting points of the materials used. Using both a UAM process and a brazing process enables more complex parts to be created using UAM and combined in a lower cost brazing process to form the manifold structure. - Using UAM, the finstock layers are arranged to optimize heat transfer through the manifold structure, such as in a direction normal to the heated surface. Increasing efficiency of the cooling function performed by the manifold structure allows for improved thermal performance of manifold structures used for cooling high power electronics. Applications requiring cooling manifolds may implement fewer manifolds, given the increased efficiency of the manifold structure according to the present application. Providing fewer manifold structures decreases power used to pump coolant through the manifolds, effectively reducing the overall operating costs of the electronics and associated cooling manifold structure. In aerospace applications such as radars, the manifold structure according to the present application may be implemented to allow radars to operate at a higher energy level due to the improved detection of the radar by increased efficiency of cooling the circuitry.
- Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a "means") used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application, within the scope of the claims.
Claims (15)
- A manifold structure (20) having at least one flow passage, the manifold structure comprising:a center manifold section (28) formed of a metal material and having at least one machined cavity in communication with the at least one flow passage; anda plurality of ultrasonic additively manufactured finstock (38) layers that are arranged within the flow passage and segment the flow passage into a plurality of flow cavities (46);wherein the finstock (38) layers are stacked in a direction normal to the center manifold section (28) and permanently joined to the center manifold section (28); andwherein the finstock (38) layers are formed of a multi-material laminate material comprising dissimilar metal materials that is integrated into the metal material of the center manifold section (28).
- The manifold structure of claim 1, wherein the finstock (38) layers are welded or brazed to the center manifold section (28).
- The manifold structure of claim 1 or 2, wherein the center manifold section (28) is formed of aluminum; and preferably, wherein the multi-material laminate material includes an aluminum material.
- The manifold structure of claim 3, wherein the multi-material laminate material further includes at least one of copper, molybdenum, tungsten, titanium, or silicon carbide.
- The manifold structure of any of claims 1-4, wherein the center manifold section (28) extends along a horizontal axis (22), and the finstock layers have bond joints (38a) that are arranged at angles greater than ten degrees relative to the horizontal axis.
- A manifold structure (20) having at least one flow passage, the manifold structure comprising:a center manifold section (28) that is formed of a metal material and has at least one machined cavity; anda plurality of ultrasonic additively manufactured finstock (38) layers that are arranged within the flow passage and segment the flow passage into a plurality of flow cavities (46);wherein the finstock (38) layers are stacked in a direction normal to the center manifold section (28) and permanently joined to the center manifold section (28); andwherein the center manifold section (28) extends along a horizontal axis (22), and at least one of the finstock (38) layers has a bond joint that is arranged at an angle greater than ten degrees relative to the horizontal axis.
- The manifold structure of claim 6, wherein the finstock (38) layers are formed of more than one metal material.
- The manifold structure of claim 6 or 7, wherein the finstock (38) layers are formed of a multi-material laminate material.
- The manifold structure of any of claims 6-8, wherein the center manifold section (28) is formed of aluminum; and
preferably, wherein the finstock (38) layers are formed of aluminum and at least one second material that is embedded within the aluminum; and
preferably, wherein the at least one second material is copper, molybdenum, tungsten, titanium, or silicon carbide. - The manifold structure of any of claims 6-9, wherein the manifold structure is a heat exchanger.
- The manifold structure of any of claim 6-9, wherein the manifold structure includes at least one vacuum brazed cold plate.
- A method of forming a manifold structure (20) having at least one flow passage, the method comprising:forming (82) a plurality of finstock (38) layers using an ultrasonic additive manufacturing process;forming (94) a center manifold section (28) of a metal material;machining (96) the center manifold to form at least one cavity;arranging the plurality of finstock (38) layers within the at least one cavity of the center manifold section (28) to segment the at least one cavity into a plurality of flow cavities (46); andpermanently joining (96) the plurality of finstock (38) layers to the center manifold section (28);wherein the the finstock (38) layers are formed of a multi-material laminate material comprising dissimilar metal materials that is integrated into the metal material of the center manifold section (28).
- The method of claim 15, wherein permanently joining the finstock (38) layers to the center manifold section (28) includes using a brazing process or a welding process; and
preferaby, further comprising:forming the plurality of finstock (38) layers of an aluminum material; andvacuum brazing the plurality of finstock (38) layers to the center manifold section (28) using a filler material that is formed of the aluminum material of the finstock (38) layers. - The method of any of claim 12 or claim 13, wherein forming the plurality of finstock (38) layers includes:forming a first layer, wherein the first layer is formed of a first metal material (56); andembedding a second layer within the first layer for heat spreading, wherein the second layer is formed of a second metal material (58).
- The method of any of claims 12-14, wherein the center manifold section (28) extends along a horizontal axis (22), and forming the finstock (38) layers includes arranging bond joints of the finstock (38) layers at angles greater than ten degrees relative to the horizontal axis.
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US15/486,724 US10766097B2 (en) | 2017-04-13 | 2017-04-13 | Integration of ultrasonic additive manufactured thermal structures in brazements |
PCT/US2018/025003 WO2018191017A1 (en) | 2017-04-13 | 2018-03-29 | Integration of ultrasonic additive manufactured thermal structures in brazements |
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US20180297144A1 (en) | 2018-10-18 |
US10766097B2 (en) | 2020-09-08 |
WO2018191017A1 (en) | 2018-10-18 |
EP3610215A1 (en) | 2020-02-19 |
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